Aqueous binder for granular and/or fibrous substrates

Patent metadata

Field	Value
Publication number	US-9238749-B2
Application number	US-201213370762-A
Country	US
Kind code	B2
Filing date	Feb 10, 2012
Priority date	Feb 14, 2011
Publication date	Jan 19, 2016
Grant date	Jan 19, 2016

Abstract

Aqueous binders for granular and/or fibrous substrates are based on polyacids and polyols.

First claim

We claim:

1. An aqueous binder, comprising as active constituents:
a polymer A obtained by free-radical polymerization, the polymer comprising >5 wt% and <100 wt% of an α,β-monoethylenically unsaturated monocarboxylic acid or an α,β-monoethylenically unsaturated dicarboxylic acid in polymerized form,
a polyol compound B having at least two hydroxyl groups and a molecular weight of <1000 g/mol, and
a salt compound C which at 20° C. and 1 atm absolute has a solubility of >10 g in 100 g of deionized water;
wherein the salt compound C is selected from the group consisting of sodium chloride, potassium chloride, sodium sulfate, and potassium sulfate, the amount of salt C is >0.1 and <40 wt %, based on summed total amounts of polymer A and polyol B, the aqueous binder comprises no phosphorus-containing reaction accelerants and the weight ratio of polymer A to polyol B is in the range of 100:1 to 1.5:1.

2. The aqueous binder according to claim 1 , wherein the polymer A comprises at least one compound in polymerized form that is selected from the group consisting of acrylic acid, methacrylic acid, crotonic acid, fumaric acid, maleic acid, maleic anhydride, 2-methylmaleic acid and itaconic acid.

3. The aqueous binder according to claim 1 , wherein the polymer A is constructed exclusively of an α,β-monoethylenically unsaturated mono- or dicarboxylic acid in polymerized form.

4. The aqueous binder according to claim 1 , wherein the polyol B is an alkanolamine.

5. The aqueous binder according to claim 1 , wherein the polyol B is triethanolamine.

6. The aqueous binder according to claim 1 , wherein the salt C is at least one selected from the group consisting of sodium chloride, potassium chloride, and sodium sulfate.

7. The aqueous binder according to claim 1 , wherein a weight ratio of polymer A to polyol B, based on solids, is from 50:1 to 2:1.

8. The aqueous binder according to claim 1 , wherein an equivalence ratio of carboxyl groups of polymer A to hydroxyl groups of polyol B is from 20:1 to 1:1.

9. The aqueous binder according to claim 1 , wherein an amount of salt C is from 5 to 40 wt%, based on summed total amounts of polymer A and polyol B.

10. The aqueous binder according to claim 1 , wherein the binder is suitable for production of shaped articles from granular substrates, fibrous substrates, or both.

11. A process for producing a shaped article from granular substrates, fibrous substrates, or both, the process comprising: applying the aqueous binder according to claim 1 to the granular substrate, fibrous substrate, or both;
optionally shaping the granular substrate, fibrous substrate, or both, treated with the aqueous binder; and then
subjecting the granular substrate, fibrous substrate, or both, thus treated, to a thermal treatment at a temperature of >110° C.

12. The process according to claim 11 , wherein the granular substrate, fibrous substrate, or both are a mechanically consolidated or chemically prebonded fiber web.

13. A shaped article obtained by the process according to claim 11 .

14. An aqueous binder, consisting essentially of as active constituents:
a polymer A obtained by free-radical polymerization, the polymer comprising >5 wt% and <100 wt% of an α,β-monoethylenically unsaturated monocarboxylic acid or an α,β-monoethylenically unsaturated dicarboxylic acid in polymerized form,
a polyol compound B having at least two hydroxyl groups and a molecular weight of <1000 g/mol, and
a salt compound C which at 20° C. and 1 atm absolute has a solubility of >10 g in 100 g of deionized water;
wherein the salt compound C is selected from the group consisting of sodium chloride, potassium chloride, sodium sulfate, and potassium sulfate, the amount of salt C is >0.1 and <40 wt%, based on summed total amounts of polymer A and polyol B, and the weight ratio of polymer A to polyol B is in the range of 100:1 to 1.5:1.

15. The aqueous binder according to claim 14 , wherein the salt C is at least one selected from the group consisting of sodium chloride, potassium chloride, and sodium sulfate.

16. The aqueous binder according to claim 14 , wherein the polymer A comprises at least one compound in polymerized form that is selected from the group consisting of acrylic acid, methacrylic acid, crotonic acid, fumaric acid, maleic acid, maleic anhydride, 2-methylmaleic acid and itaconic acid.

17. The aqueous binder according to claim 14 , wherein the polymer A is constructed exclusively of an α,β-monoethylenically unsaturated mono- or dicarboxylic acid in polymerized form.

18. The aqueous binder according to claim 14 , wherein the polyol B is an alkanolamine.

19. The aqueous binder according to claim 14 , wherein the polyol B is triethanolamine.

Assignees

• Michl Kathrin
• Braun Markus
• Kalbe Michael
• Basf Se

Inventors

• Michl Kathrin
• Braun Markus
• Kalbe Michael

Classifications

• C09D133/14 Primary

  of esters containing halogen, nitrogen, sulfur or oxygen atoms in addition to the carboxy oxygen · CPC title

• C08L2201/54

  Aqueous solutions or dispersions · CPC title

• Y10T428/249921

  Web or sheet containing structurally defined element or component · CPC title